Support Bracket For Rod Assembly

ABSTRACT

There is provided a bracket and rod assembly system having improved strength and configured to allow complete access of a drapery supported by the rod assembly to an entire length of the rod assembly without interference from the bracket.

FIELD

The present invention relates generally to a support bracket for a rod assembly and, more particularly, to a support bracket for a rod assembly that exhibits improved strength and is configured to allow complete access of a drapery supported by the rod assembly to an entire length of the rod assembly without interference from the bracket.

BACKGROUND

Brackets have long been used for mounting drapery rods, shower curtain rods, and other rods to surfaces such as walls, windows, window frames, window casings, and ceilings. These brackets are offered in many different shapes and sizes and range from highly ornamental designs to simpler utilitarian designs. Often, these brackets have an “L-shaped” configuration, where an arm portion extends horizontally over the top of a vertically-extending mounting portion, and comprise a hook-like feature in which the rod rests, or a ring through which the rod passes. In some commercial embodiments, the rod is allowed to freely rotate and slide back and forth on the bracket. In other commercial embodiments, the rod is secured by the user screwing a set screw through the bracket until it contacts the outer surface of the rod. Often, in such configurations the set screws loosen over time due to repeated movement of the drapery horizontally during regular use and vertically when the drapery is pulled on from below.

In any event, the rod-attachment portion of such brackets are typically visible from the front and contribute to an interrupted appearance of the rod's profile. Such brackets also restrict movement of the drapery along the entire length of the rod, thereby preventing complete drapery coverage along the entire length of the rod. In some instances, rings are used to suspend the drapery from the rod. Complete coverage may be obtained by placing some of the rings outside of the bracket. However, in this configuration the bracket would still be visible from the front and movement of the curtain from side to side is still restricted by the position of the bracket.

Another drawback of conventional brackets is their lack of strength due their “L-shaped” configuration. Conventional “L-shaped” brackets utilize horizontal interfaces or bends where the horizontally-extending arm of the bracket meets the vertically-extending mounting portion. These horizontal interfaces are prone to bending when suspending a heavy rod and/or drapery from the rod attachment portion or when the drapery is pulled downward during use, such as, for example, when opening and closing, cleaning, or children playing behind the drapery.

Therefore, there is a need for a bracket and a rod assembly system that permits complete coverage of the drapery along the entire length of the rod and maximizes drawback without any restriction of movement of the drapery due to the bracket position. There is also a need to provide a bracket that locks the rod in place such that the rod is not permitted to move laterally. Further, there is a need to address load support problems inherent to brackets when heavy drapery is used or when repeated downward force is applied to the rod.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a double rod assembly.

FIG. 2 is a perspective view of a double rod assembly showing a slightly exploded view of the rod, first rod-attachment portion, and finial.

FIG. 3 is a perspective view of a single rod assembly showing a slightly exploded view of the rod, first rod-attachment portion, and finial.

FIG. 4 is a perspective view of a bracket.

FIG. 5 is a top plan view of the bracket in FIG. 4.

FIG. 6 is a rear view of the bracket in FIG. 4.

FIG. 7 is a side view of the bracket in FIG. 4

FIG. 8 is a perspective view of an alternate embodiment of a bracket.

FIG. 9 is a top plan view of the bracket in FIG. 8.

FIG. 10 is an exploded view of a rod assembly in which a recessed rod end is used.

FIG. 11 is a perspective view of the assembled rod and bracket in FIG. 10

FIG. 12 is an exploded view of rod assembly in which a recessed finial is used.

FIG. 13 is an exploded view of an alternate rod assembly where the first rod-attachment portion is visible when assembled.

FIG. 14 is a perspective view of the alternate rod assembly in FIG. 13.

FIG. 15 illustrates various embodiments of the bracket and rod assembly where the outer profile of the rounded terminal end of the rod attachment portion may be larger, smaller, or equal to the outer profile of the rod.

FIG. 16 is a perspective view of a double rod assembly using a curved bracket.

FIG. 17 is a perspective view of the curved bracket in FIG. 16.

FIG. 18 is a top plan view of the curved bracket in FIG. 16 in a left-handed configuration.

FIG. 19 is a top plan view of the curved bracket in FIG. 16 in a right-handed configuration.

FIG. 20 is a side view of the curved bracket in FIG. 16

FIG. 21 is a rear view of the curved bracket in FIG. 16

FIG. 22 is a front view of the curved bracket in FIG. 16

DETAILED DESCRIPTION

With reference to FIGS. 1-3, there is illustrated a system for supporting a rod 40 from which a swatch material such as, for example, a drapery or curtain 60 may be suspended. The system includes a bracket 10, a rod 40, and a finial 50, which may be formed of any suitable material such as, for example, steel, zinc, aluminum, wood, various forms of plastic, and mixtures thereof. The bracket 10 may be mounted on a surface such as, for example, a wall surface or a window frame. The finial 50 may attach to the end portion of rod 40 such that the bracket 10 is between the end of the rod 40 and the finial 50. The finial 50 may be attached to the rod 40 by any conventional means such as, for example, a threaded screw. The rod assembly system may be configured to support a single rod 40, as illustrated in FIG. 3, or a second rod 70 may be attached to the bracket 10, as illustrated in FIG. 2, which may be used to support a second swatch material such as, for example a sheer 90, as illustrated in FIG. 1.

With reference to FIGS. 4-7, the bracket 10 may include a mounting portion 12, an arm portion 14, and a first rod-attachment portion 20. The mounting portion 12, arm portion 14, and first rod-attachment portion 20 of bracket 10 may comprise a single material or may comprise different materials, and may be integrally formed or may comprise separately-formed components. The mounting portion 12 may comprise any shape and may include a back surface 26 that is substantially flat, and is configured to allow the bracket 10 to be mounted on a surface such as, for example, a wall. The mounting portion 12 may be mounted to the wall using any conventional means such as, for example, threaded screws and drywall anchors.

The arm portion 14 may extend outwardly from the mounting portion 12 and may include a proximal segment 16 and a distal segment 18. The arm portion 14 may be shaped such that the distal segment 18 may be substantially parallel to the back surface 26 of the mounting portion 12, and the proximal segment 16 may be substantially parallel to a first rod-attachment portion 20 disposed at the distal segment 18 of the arm portion 14. Alternatively, the arm portion 14 may have a linear configuration, as shown in FIGS. 8 and 9. The arm portion 14 may also have a curved shape, as illustrated in FIGS. 16-22.

The first rod-attachment portion 20 may include a rounded terminal end in which an opening 22 is formed. The opening 22 may be, for example, an aperture, or the opening 22 may be, for example, a partial opening that has been cut out or voided from the first rod-attachment portion 20. The opening 22 may be configured to accept a fastener 100 that attaches the rod 40 to the finial 50, as illustrated in FIGS. 10, 12, and 13. The first rod-attachment portion 20 may have a uniform width, or the outer profile of the terminal end of the rod-attachment portion 20 may have a width that is larger than the width of the end of the first rod attachment portion that attaches to the distal segment 18 of the arm portion 14. As shown in FIG. 15, the outer profile of the terminal end of the rod-attachment portion 20 may be larger, smaller, or equal in size to the diameter of the rod 40, depending on the configuration of the rod 40 and the finial 50 to be used.

In some embodiments, as illustrated in FIG. 4, the bracket 10 may also include a second rod-attachment portion 24, which may be disposed in the proximal segment 16 of the arm 14. The second rod-attachment portion 24 includes an opening such as, for example, an aperture to accept a fastener that attaches a second rod 70 to a second finial 80. The opening may also be a partial opening configured such that second rod 70 may be lowered into the opening, as illustrated in FIG. 16.

In a preferred embodiment of the bracket 10, the mounting portion 12 may have a vertically-extending longitudinal axis and may be configured to be mounted to a wall using screws that may be aligned vertically. The proximal segment 16 of arm portion 14 may extend horizontally in a vertical plane from the mounting portion 12 in a direction that is substantially perpendicular to the longitudinal axis the mounting portion 12. The interface 13 between the mounting portion 12 and the proximal segment 16 may extend vertically along an axis that is substantially parallel to the longitudinal axis of the mounting portion 12. The length of the proximal segment 16 may be, for example, between two and three inches.

The distal segment 18 of the of arm portion 14 may extend from the proximal segment 16 in a direction that is substantially parallel to the back surface 26 of the mounting portion 12 and substantially perpendicular to the proximal segment 16, such that the distal segment 18 does not cross in front of the mounting portion 12. The interface 17 between the proximal segment 16 and distal segment 18 may extend vertically along an axis that is substantially parallel to the longitudinal axis of mounting portion 12. The length of the distal segment 18 may be, for example, between one and two inches.

The first rod-attachment portion 20 may extend from the distal segment 18 in a direction that is substantially parallel to the proximal segment 16. The interface 19 between the distal segment 18 and the first rod-attachment portion 20 may extend vertically along an axis that is substantially parallel to the longitudinal axis of the mounting portion 12. The length of the first rod-attachment portion from its opening 22 to the interface 19 where the first rod-attachment portion 20 meets distal segment 18 may be less than an inch. The vertical axis of each of interface 13, interface 17, and interface 19 may be substantially parallel to one another. The vertically-extending interfaces increase the strength of the bracket so to prevent failure through bending of the bracket at the interfaces when downward force is applied to the rod attachment portion. By contrast, conventional “L-shaped” brackets, where an arm portion extends horizontally over the top of a vertical mounting portion (where the interfaces are horizontal), are susceptible to bending at the horizontally-aligned wall bend interface when downward force is applied to the rod attachment portion.

FIGS. 8 and 9 illustrate an embodiment of the bracket 10 where the arm portion 14 has a linear configuration, but may otherwise be similar to the preferred embodiment described above. In this linear configuration, the arm portion 14 may bridge the mounting portion 12 and the first rod-attachment portion 20 such that the proximal segment 16 may form an obtuse angle 30 with the mounting portion 12, and the distal segment 18 may form an obtuse angle 32 with the first rod-attachment portion 20. The obtuse angle 30 at which the arm portion 14 extends from the mounting portion 12 may be, for example, between about 110° to about 130°, and the obtuse angle 32 at which the first rod-attachment portion extends from the distal segment 18 may be, for example, between about 135° to about 155°. The length of the arm portion 14 may be, for example, between two and three inches. In this configuration, the proximal segment 16 and the distal segment 18 may be coplanar. The interface 13 between the mounting portion 12 and the proximal segment 16, and the interface 19 between the distal segment 18 and the first rod-attachment portion 20, may extend vertically along axes that are substantially parallel to the longitudinal axis of the mounting portion 12.

FIGS. 16-22 illustrate a bracket 10 that has a curved shape as an alternative to the angular shapes depicted in FIGS. 1-14. In this configuration, the mounting portion 12, first rod-attachment portion 20, and second rod-attachment 24 portion may have the same configuration, components, and attributes as described above for the angular brackets. As shown in FIGS. 16 and 21, the mounting portion 12 may have a vertically-extending longitudinal axis and may be configured to be mounted to a wall using one or more screws and/or anchors that may be aligned vertically.

In the curved embodiment of bracket 10 illustrated in FIGS. 16-22, the proximal segment 16 may initially extend horizontally from the mounting portion 12 via an interface 13 in a direction that is substantially perpendicular to the back surface 26 of the vertically-extending mounting portion 12. The proximal segment 16 may then gradually curve away from the center axis of the mounting portion 12 such that the distal segment 18, disposed at the end of the proximal segment 16 via interface 17, does not cross in front of the mounting portion 12. The distal segment 18 may curve in the same direction as the proximal segment 16. The first rod-attachment portion 20, disposed at the terminal end of the distal segment 18 via interface 19, may extend horizontally in the same direction that the proximal segment 16 initially extends. In this configuration, the interface 13, interface 17, and interface 19 may each extend vertically along an axis that is substantially parallel to the longitudinal axis of the mounting portion 12.

In the curved embodiment, bracket 10 may include a second rod-attachment portion 24 disposed in the proximal segment 16 of the arm 14. The second rod-attachment portion 24 may comprise a partial opening configured such that second rod 70 may be lowered into the opening. As shown in FIG. 16, the second rod 70 may be secured to the second rod-attachment portion 24 in its resting position by a fastener such as, for example, a set screw.

Specific embodiments of the bracket and system described herein are presented below in more detail. In each embodiment, the bracket and system are configured such that the rod may extend in a gap that is created between the longitudinal axis of the proximal segment and the longitudinal axis of the first rod-attachment portion such that the bracket does not interrupt movement of the drapery along the length of the rod and allows maximum drawback of the drapery. In embodiments described below, the bracket may have an angular shape, as illustrated in FIGS. 1-14, or a curved shape, as illustrated in FIGS. 16-22.

In an embodiment illustrated in FIGS. 10 and 11, the first rod-attachment portion 20 may have a rounded terminal end having an outer profile that may be smaller in size than the diameter 46 of the rod 40. In this configuration, the rod 40 includes a recess 42 that has been formed in the end of the rod 40 for accepting the first rod-attachment portion 20 of the bracket 10. The recess 42 may be shaped such that at least a portion of the terminal end of the first rod-attachment portion 20 is concealed when the finial 50, first rod-attachment portion 20, and end portion of the rod 40 are in an assembled configuration. The recess 42 may also have the same shape as the terminal end of first rod-attachment portion 20. An arcuate notch 48 formed in the terminal end of the rod 40 allows the first rod-attachment portion 20 to extend from the recess 42. The first rod-attachment portion 20 may be embedded in the recess 42 in the end portion of the rod 40 such that the edge 44 of the end portion of the rod 40 is able to contact the finial 50 and the edge 28 of the terminal end of the first rod-attachment portion 20 is not visible when the rod 40, the first rod-attachment portion 20, and finial 50 are assembled.

An alternate embodiment is illustrated in FIG. 12. In this configuration, the first rod-attachment portion 20 may have a rounded terminal end having an outer profile that may be smaller in size than the diameter 46 of the rod 40. In this configuration, the finial 50 includes a recess 52 that has been formed in the end of the finial 50 for accepting the first rod-attachment portion 20 of the bracket 10. The recess 52 may be shaped such that at least a portion of the terminal end of the first rod-attachment portion 20 is concealed when the finial 50, first rod-attachment portion 20, and end portion of the rod 40 are in an assembled configuration. The recess 52 may also have the same shape as the first rod-attachment portion 20. The finial 50 may include an arcuate notch 54, which allows the first rod-attachment portion 20 to extend from the recess 52. The first rod-attachment portion 20 may be embedded in the recess 52 in the end portion of the finial 50 such that the edge 44 of the end portion of the rod 40 is able to contact the finial 50 and the edge 28 of the terminal end of the first rod-attachment portion 20 is not visible when the rod 40, the first rod-attachment portion 20, and finial 50 are assembled.

In another embodiment illustrated in FIGS. 13 and 14, the first rod-attachment portion 20 is not embedded in the rod 40 or the finial 50, and instead acts as an interface between the rod 40 and finial 50 such that the rod 40 and finial 50 do not contact each other. In this configuration, the ends of the rod 40 and finial 50 that contact the first rod-attachment portion 20 may have a substantially flat surface. The first rod-attachment portion 20 of bracket 10 may have a rounded terminal end having an outer profile that may be equal to or larger in size than the outer diameter 46 of the rod 40 such that edge 28 of the terminal end of the first rod-attachment portion 20 may be visible when the rod 40, first rod-attachment portion 20, and finial 50 are assembled. The rounded terminal end may also be smaller in size than the outer diameter 46 of the rod 40. FIG. 15 illustrates various embodiments of the bracket and rod assembly where the outer profile of the rounded terminal end of the rod attachment portion may be larger, smaller, or equal to the outer profile of the rod.

It will be understood that various changes in the details, materials, and arrangements of parts and components which have been herein described and illustrated in order to explain the nature of the bracket and rod assembly system may be made by those skilled in the art within the principle and scope of the bracket and rod assembly system as expressed in the appended claims. Furthermore, while various features have been described with regard to particular embodiments, it will be appreciated that features described for one embodiment also may be incorporated with the other described embodiments. 

What is claimed is:
 1. A mounting bracket comprising: a mounting portion having a vertically-extending longitudinal axis and a back surface that defines a first plane; an arm portion having a proximal segment and a distal segment, the proximal segment being attached to the mounting portion such that the arm portion initially extends outwardly from the mounting portion in a second plane; and a first rod-attachment portion disposed at the distal segment of the arm portion and extending in a third plane that is substantially perpendicular to the first plane, the first rod-attachment portion having an opening formed therein.
 2. The bracket of claim 1, wherein the arm portion comprises a second rod-attachment portion disposed between the distal segment and the proximal segment of the arm portion, the second rod-attachment portion having an opening formed therein.
 3. The bracket of claim 1, wherein the mounting portion, arm portion, and first rod-attachment portion comprise a single piece of material.
 4. The bracket of claim 1, wherein the arm portion comprises a curved portion.
 5. The bracket of claim 1, wherein the arm portion is shaped such that the distal segment of the arm portion is substantially parallel to the back surface of the mounting portion and the proximate segment of the arm portion is substantially parallel to the first rod-attachment portion.
 6. The bracket of claim 1, wherein the proximal segment of the arm portion forms an obtuse angle with the mounting portion, and the distal segment of the arm portion forms an obtuse angle with the first rod-attachment portion.
 7. The bracket of claim 1, wherein the opening in the first rod-attachment portion is an aperture for accepting a fastener that attaches a finial to a rod.
 8. The bracket of claim 2, wherein the opening in the second rod-attachment portion is an aperture for accepting a fastener that attaches a finial to a rod.
 9. The bracket of claim 1, further comprising a vertically-extending interface disposed between the mounting portion and the proximal segment of the arm portion and a vertically-extending interface disposed between the distal segment of the arm portion and the first rod-attachment portion, the vertically-extending interfaces being parallel to the longitudinal axis of the mounting portion.
 10. A system for mounting a rod to a surface, the system comprising: a rod having an end portion; a finial; and a bracket that comprises a mounting portion having a vertically-extending longitudinal axis and a back surface that defines a first plane; an arm portion having a proximal segment and a distal segment, the proximal segment being attached to the mounting portion such that the arm portion initially extends outwardly from the mounting portion in a second plane; and a first rod-attachment portion disposed at a first terminal end of the distal segment of the arm portion and extending in a third plane that is substantially perpendicular to the first plane, the first rod-attachment portion having a second terminal end in which an opening is formed.
 11. The system of claim 10, wherein the mounting portion, arm portion, and first rod-attachment portion comprise a single piece of material.
 12. The system of claim 10, wherein the arm portion of the bracket comprises a curved portion.
 13. The system of claim 10, wherein the arm portion of the bracket is shaped such that the distal segment of the arm portion is substantially parallel to the back surface of the mounting portion and the proximate segment of the arm portion is substantially parallel to the first rod-attachment portion.
 14. The system of claim 10, wherein the proximal segment of the arm portion forms an obtuse angle with the mounting portion, and the distal segment of the arm portion forms an obtuse angle with the first rod-attachment portion.
 15. The system of claim 10, wherein the opening in the first rod-attachment portion is an aperture for accepting a fastener that attaches the finial to the rod.
 16. The system of claim 10, wherein the end portion of the rod includes a recess for accepting the first rod-attachment portion of the bracket such that at least a portion of the terminal end of the first rod-attachment portion is concealed when the finial, first rod-attachment portion, and end portion of the rod are in an assembled configuration.
 17. The system of claim 16, wherein the recess in the end portion of the rod has a shape capable of receiving a portion of the first rod-attachment portion.
 18. The system of claim 10, wherein an outer profile of the terminal end of the first rod-attachment portion is smaller than a diameter of the end portion of the rod.
 19. The system of claim 16, wherein the rod has a notch and the first rod-attachment portion extends through the notch.
 20. The system of claim 10, wherein the finial includes a recess for accepting the first rod-attachment portion of the bracket such that the finial is able to conceal at least a portion of the terminal end of the first rod-attachment portion when the finial, first rod-attachment portion, and end portion of the rod are in an assembled configuration.
 21. The system of claim 20, wherein the recess in the finial has a shape capable of receiving a portion of the first rod-attachment portion.
 22. The system of claim 20, wherein the recess in the finial has an opening and the first rod-attachment portion extends through the opening.
 23. The system of claim 10, wherein an outer profile of the terminal end of the first rod-attachment portion is smaller than a diameter of the end portion of the rod.
 24. The system of claim 10, wherein the first rod-attachment portion provides an interface between the finial and the end portion of the rod such that the finial does not contact the end portion of the rod when the finial, first rod-attachment portion, and end portion of the rod are in an assembled configuration.
 25. The system of claim 10, wherein an outer profile of the terminal end of the first rod-attachment portion is equal to or larger than a diameter of the end portion of the rod.
 26. The system of claim 10, wherein the arm portion comprises a second rod-attachment portion disposed along the arm portion, the second rod-attachment portion having an opening formed therein.
 27. The system of claim 26, further comprising a second rod having a diameter that is smaller than an outer profile of the second rod-attachment portion.
 28. The system of claim 26, wherein the opening in the second rod-attachment portion is an aperture.
 29. The system of claim 10, wherein the rod is capable of suspending a swatch material and the bracket does not restrict movement of the swatch material along the rod when the rod, bracket, and finial are in an assembled configuration.
 30. The system of claim 10, wherein the bracket further comprises a vertically-extending interface disposed between the mounting portion and the proximal segment of the arm portion and a vertically-extending interface disposed between the distal segment of the arm portion and the first rod-attachment portion, the vertically-extending interfaces being parallel to the longitudinal axis of the mounting portion. 